Sheet metal intersection studs

ABSTRACT

A corner stud ( 40 ) has a four-sided post portion ( 42 ) that sits into a corner region of a framing wall. The post portion includes a pair of flanges ( 92, 96 ) which form a right angle inside corner at the inside corner of the framing wall. Edge portions of wallboard panels ( 108, 110 ) connect to the flanges ( 92, 96 ). A post portion  112  of an intersection stud ( 110 ) fits within the tracks at a location between the corners. Inside corners are formed by flanges ( 148, 160 ) and ( 154, 166 ) against which edge portions ( 180, 182 ) of wallboard panels ( 184, 186 ) and ( 188, 190 ) are connected. The edge portions ( 180, 182, 188, 190 ) of the wallboard are connected to and backed up by the flanges ( 148, 160, 154, 166 ).

TECHNICAL FIELD

This invention relates to sheet metal framing walls. More particularly,it relates to the provision of studs usable where two walls intersect,for facilitating the connection together of the two walls.

BACKGROUND OF THE INVENTION

Building walls intersect each other at corners and at locations betweenthe corners. U.S. Pat. No. 4,689,930, granted Sep. 1, 1987, to Robert J.Menchetti, discloses a corner stud to which two standard studs areconnected. U.S. Pat. No. 3,363,377, granted Jan. 16, 1968, to Melvin H.Beckman, and U.S. Pat. No. 4,283,892, granted Aug. 18, 1981, to Larry B.Brown disclose studs constructed to be usable at an intersection of afirst wall with a second wall between its corners. FIG. 1 of the drawingherein shows a prior art use of two standard studs where two wallsintersect at a corner. FIG. 3 of the drawing herein shows the use of twostandard prior art studs at an intersection of two walls between thecorners.

There is a need for intersection studs for use at the corners andbetween the corners that facilitates construction of the walls whilereducing both material and labor. It is the primary object of thepresent invention to fill this need.

BRIEF SUMMARY OF THE INVENTION

According to the invention, a corner stud is provided that has generallytubular post portion which fits into the corner regions of the upper andlower tracks where they meet at the corners and which includes flangesforming a right angle inside corner to which edge portions of wallboardpanels are secured.

It is also an object of the invention to provide an intersection studwhich fits into the upper and lower tracks between the corners of a walland which includes a pair of flanges that project into the upper andlower tracks of an intersecting wall, and to which edge portions ofwallboard panels are secured.

In preferred form, a sheet metal corner stud incorporating the inventioncomprises a first wall, a second wall, a third wall and a fourth wall.The first wall has a first edge and a second edge. The second wall had afirst edge and a second edge. The third wall has first edge and a secondedge. The fourth wall has a first edge and a second edge. The secondedge of the first wall is connected to the first edge of the secondwall. The second edge of the second wall is connected to the first edgeof the fourth wall. The second edge of the third wall is connected tothe first edge of the fourth wall. A first flange is provided that has afirst edge that is connected to the first edge of the first wall. Thefirst flange extends from the first wall in a direction opposite fromthe direction that the second wall extends from the first wall. A secondflange is provided that has a first edge that is connected to the secondedge of a fourth wall. The second flange extends from the fourth wall ina direction opposite from the direction that the third wall extends fromthe fourth wall. The first flange has an outer surface and the secondflange has an outer surface. The first flange extends substantiallyperpendicular to the second flange.

The between-the-corners intersection stud preferably comprises a firstwall having a first edge and a second edge, a second wall having a firstedge and a second edge, and a third wall having a first edge and asecond edge. The second edge of the first wall is connected to the firstedge of the second wall. The second wall extends perpendicular from thefirst wall. The second edge of the second wall is connected to the firstedge of the third wall. The third wall extends perpendicular from thesecond wall and in spaced apart parallelism with the first wall. Thestud includes a first flange having a first edge and a second edge. Thefirst edge is connected to the first edge of the first wall. The firstflange extends perpendicular from the first wall. The stud includes asecond flange having a first edge and a second edge. The first edge isconnected to the second edge of the third wall. The second flangeextends perpendicular from the third wall towards and in co-planarparallelism with the first flange. A third flange has a first edge and asecond edge. The first edge is connected to the second edge of the firstflange. The third flange extends perpendicular from the first flange ina direction opposite the direction that the first wall extends from thefirst flange. A fourth flange has a first edge and a second edge. Thefirst edge is connected to the second edge of the second flange. Thefourth flange extends perpendicular from the second flange in adirection opposite from the direction that the third sidewall extendsfrom the second flange. The third flange and the fourth flange extend inspaced apart parallelism with each other. The intersection stud has awidth dimension extending between the outside surface of the second walland the outside surfaces of the first and second flanges which issubstantially equal to the width dimension between the outside surfaceof the third flange and the outside surface of the fourth flange.

Another object of the present invention is to provide an intersectionstud positionable at a corner where two walls meet which has a firstsided post portion that fits inside end portions of upper and lowertracks, and flanges which project from the post portion perpendicular toeach other inside the upper and lower tracks adjacent the corner post.

Another object of the invention is to provide an intersection studbetween the corners which has a post portion that fits into upper andlower tracks at a location between corners and includes a pair offlanges which project from the post into end portions of upper and lowertracks that intersect the tracks in which the post portion is situated.

Other objects, advantages and features of the invention will becomeapparent from the description of the best mode set forth below, from thedrawings, from the claims and from the principals that are embodied inthe specific structures that are illustrated and described.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Like reference numerals are used to designate like parts throughout theseveral views of drawing, and:

FIG. 1 is a cross sectional view taken at a corner formed where twowalls meet, showing a prior art arrangement of conventional studs atsuch corner;

FIG. 2 is a cross sectional view of a corner stud embodying the presentinvention;

FIG. 3 is a cross sectional view of a prior art intersectionconstruction between corners;

FIG. 4 is a cross sectional view of an inner section stud of the presentinvention that is utilized at an intersection between corners;

FIG. 5 is an exploded pictorial view of the corner stud shown by FIG. 2,showing the lower portion of the stud within the intersecting lowertracks and showing the intersecting upper tracks spaced above the cornerstud;

FIG. 6 is a fragmentary pictorial view of the between-the-cornerintersection stud shown by FIG. 4, showing its lower portion within theintersecting tracks of the two walls which intersect between corners;

FIG. 7 is an exploded pictorial view of two corner components for theupper and lower tracks, performed for installation at a corner betweentwo perpendicular sections of the track;

FIG. 8 is an exploded pictorial view of track components usable at anintersection between the corners, such components being adapted to beused with three straight sections of track that meet the three ends ofthe components that is illustrated; and

FIG. 9 shows the use of miter cuts at the ends of two lengths of trackfor making a right angle at a corner where the lengths of tracks meet.

DETAILED DESCRIPTION OF THE ILLUSTRATED INVENTION

For background purposes, FIGS. 1 and 3 show prior art assemblies whereone wall intersects another wall. FIG. 1 shows an intersection at acorner. FIG. 3 shows an intersection between corners. Referring to FIG.1, a first stud 10 is provided at the end of a first wall 12. A secondstud 10 is shown at the end of a second wall 14. Stud 10 includes aflange 16. A wall board panel 18 is attached to the wall 12 in themanner shown. End portion 20 of the panel 18 is connected to the studflange 16. Then, the web 22 is positioned against wall board panel 18,in the manner illustrated. Web 22 is suitably secure to the stud 10.Then, wall board panel 24 is connected to stud flange 26, in the mannerillustrated.

Referring to FIG. 3, a first framing wall 28 is constructed from upperand lower tracks and a plurality of studs 30, in known-fashion. Then, awallboard wall panel 32 is connected to one side of the framing wall.Then, a stud 34 at one end of an intersecting wall 36 is connected tostud flange 38. Wall 36 comprises upper and lower tracks and a pluralityof studs interconnecting the tracks.

In the prior art arrangements shown by FIGS. 1 and 3, the metal framingmembers of the two walls are separated by wall board 12, 32.

Referring to FIGS. 2 and 5, the corner intersection stud 40,exemplifying an aspect of the invention, comprises a four-sided cornerpost 42 having upper and lower ends that fit within upper and lowertracks 44, 46, between the webs 48, 50 and 52, 54, as illustrated. Thepost portion 42 of corner stud 40 has a first wall 56 having a firstedge 58 and a second edge 60. A second wall 62 has a first edge 64 and asecond edge 66. A third wall 68 has a first edge 70 and a second edge72. A fourth wall 74 has a first edge 76 and a second edge 78. Thesecond edge of the wall 56 is connected to the first edge of wall 62.The second edge 66 of wall 62 is connected to the first edge 70 of wall68. The second edge 72 of wall 68 is connected to the first edge 76 ofwall 74. As best illustrated by FIG. 2, the post portion 42 of wall 40is positioned between the opposite flanges 80, 82 of lower track 84 forwall 86. In a perpendicular direction, the post portion has a dimensionsubstantially equal to the distance between flanges 52, 54 of track 56.In the same direction, the post portion 42 fits between flanges 48, 50of track 44. The width of wall 56 allows wall 56 to fit between flanges88, 90 of track 92.

Corner stud 40 includes a first flange 92 having a first edge 94connected to the first edge 58 of first wall 56. Flange 62 and wall 56form a right angle corner with each other. A second flange 96 has afirst edge 98 connected to the second edge 78 of fourth wall 42. Flange96 and wall 74 together form a right angle corner, as shown in FIG. 2.Flange 92 may be provided with an end flange 100 and a return flange102. In similar fashion, flange 98 may be provided with an end flange104 and a return flange 106. End flange 100 is perpendicular to flange92 and is perpendicular to return flange 102. End flange 104 isperpendicular to flange 96 and is perpendicular to end flange 106.Flanges 92, 102 are parallel and flanges 96, 106 are parallel.

As best shown by FIG. 5, the post portion 42 of corner stud 40 ispositioned at the corner of the wall, with its lower end portion withinthe intersecting tracks 46, 84. Flange 96 is positioned inwardlyadjacent flange 52. Flange 92 is positioned inwardly adjacent flange 80.At the top of the stud wall 40, flange 96 is inwardly adjacent flange 48and flange 92 is inwardly adjacent flange 86. As shown by FIG. 2,wallboard panel 108 is connected to flange 92 and wallboard panel 110 isconnected to flange 96. Accordingly, there is solid backing for thewallboard panels 108, 110 at the corner where they meet.

The between-the-corner intersection stud 110 comprises a post portion112 that fits at its bottom into a lower track and at its top into anupper track. FIG. 6 shows a lower track 114 having a web 116 and a pairof flanges 118, 120 that project upwardly from the opposite edges of theweb 116. An intersecting track 122 has a web 124 and a pair of flanges126, 128 that project upwardly from the side edges of the web 124. Aportion of the flange 116 is cut away at the end of the track 124. IfFIG. 6 is inverted, it would show intersecting upper tracks and theupper end portion of the stud 110. The post portion 112 of stud 110comprises a first wall 130 having a first edge 132 and a second edge134. A second wall 136 has a first edge 138 and a second edge 140. Afourth wall 142 has a first edge 144 and second edge 146. The secondedge 134 of the first wall 130 is connected to the first edge 138 of thesecond wall 136. The second edge 140 of the second wall 136 is connectedto the first edge 144 of the third wall 142. A first flange 148 has afirst edge 150 and a second edge 152. A second flange 154 has a firstedge 156 and a second edge 158. The first edge 150 of flange 148 isconnected to the first edge 132 of wall 130. Flange 148 extendsperpendicular to wall 130 and is in co-planar parallelism with flange154. The second edge 146 of wall 142 is connected to the first edge 158of flange 154. Flange 154 is perpendicular to the third wall 132. Athird flange 160 has a first edge 162 and a second edge 164. Edge 162 offlange 160 is connected to edge 152 of flange 148. A fourth flange 166has a first edge 168 that is connected to the second edge 156 of flange154. Flange 166 includes a second edge 168. Flanges 160, 166 areparallel to each other and are perpendicular to the flanges 148, 154.End flanges 170, 172 may be connected to the edges 164, 168 of theflanges 160, 166. Return flanges 174, 176 may be connected to the endflanges 170, 172.

The outside dimension measured from the outer surfaces of flanges 148,154 and the outer surface of second wall 36 is substantially equal tothe inside dimension between the flanges 118, 120 of the track 114. Thedistance between the outside surfaces of the flanges 160, 166 issubstantially equal to the distance between the inside surfaces offlanges 126, 128. The post portion 112 of the stud 110 is wider than thedistance between the inside surfaces of the flanges 126, 128.

FIG. 4 is a sectional view in a mid portion of the stud 110. It showsedge portions 180, 182 of wallboard panels 184, 186 being outwardlyadjacent the flanges 148, 154. Preferably the wallboard is connected tothe flanges 148, 154. Wall board edge portions 186, 188 are outwardlyadjacent the flanges 160, 166. Preferably, these wallboard edges 186,188 are connected to the flanges 160, 166, such as by use of screws. Asshown by FIG. 4, the wallboard edges 180, 186 and 182, 188 are backed upwhere they meet by the flanges 148, 160 and 154, 166.

Both forms of intersection studs 40, 110 can be easily and quicklyinstalled in the upper and lower tracks and then the wallboard can beapplied to the framing members.

FIG. 7 shows a pair of corner members 200, 200′ usable at a cornerbetween two perpendicular tracks. Corner member 200, 200′ comprises an

L-shaped web 202 and flanges 204, 206, 208, 210. All four flanges 204,206, 208, 210 extend perpendicular to the web 202. Flanges 204 and 208meet and form a right angle corner and flanges 206 and 210 meet and forma right angle corner. The corner member 200 is positioned at a cornerbetween two perpendicular straight sections of track that are leadinginto the corner. The ends of the straight sections of the track may buttup against the ends of the corner member 200. Corner member 200′ is amirror image of corner member 200.

FIG. 8 shows members 212, 212′ that are each usable at an intersectionof two walls between corners. It comprises a T-shaped web 214 andflanges 216, 218, 220, 222, 224. All of the flanges 216, 218, 220, 222,224 extend perpendicular to the T-shaped web 214. Flanges 216, 218extend perpendicular to each other and meet at a right angle corner.Flanges 222, 224 extend perpendicular to each other and meet at a rightangle corner. Flange 220 extends along the outside of a straight sectionof the member 212 which is positioned between the ends of two collinearstraight sections of track. The stem portion of the member 212 includesthe flanges 218, 224 adapted to be collinear with an intersectingperpendicular section of track. Member 212′ is a mirror image of member212.

In place of using the corner member shown by FIG. 7, the ends of the twostraight section of track may be cut at a 45 degree angle as shown byFIG. 9. Then the cut ends 230, 230′, 232, 232′ of the two sections 234,234′, 236, 236′ can be brought together so that the two sections willmeet and form a right angle.

The construction shown by FIGS. 7-9 can all be used with both the toptracks and the bottom tracks.

The illustrated embodiments are only examples of the present inventionand, therefore, are non-limitive. It is to be understood that manychanges in the particular structure, materials and features of theinvention may be made without departing from the spirit and scope of theinvention. Therefore, it is my intention that my patent rights not belimited by the particular embodiments that are illustrated and describedherein, but rather are to be determined by the following claims,interpreted according to accepted doctrines of patent claiminterpretation, including use of the doctrine of equivalents andreversal of parts.

1. An intersection stud for a framing wall, comprising: a post portionhaving an upper end adapted to be fitable between the flanges of anupper track and a lower portion adapted to be fitable between theflanges of a lower track; and a pair of flanges on said post portionforming an inside corner that is adapted to be positioned to provide abacking for wallboard edges that meet at the corner.
 2. The intersectionstud of claim 1, wherein the post portion of the stud has four sides andfour corners and the two flanges extend perpendicular to each other froma common corner.
 3. The intersection stud of claim 1, wherein the postportion of the stud has three sides, a pair of co-planar flangesprojecting inwardly from two of the sides, and a pair of parallel secondflanges projecting perpendicularly from the first two flanges andforming two inside corners for backing up edge portions of wallboardmembers that meet at the corners.
 4. A sheet metal corner stud,comprising: a first wall; a second wall; a third wall; a fourth wall;said first wall having a first edge and a second edge; said second wallhaving a first edge and a second edge; said third wall having a firstedge and a second edge; said fourth wall having a first edge and asecond edge; said second edge of said first wall being connected to thefirst edge of the second wall and forming a right angle corner with thesecond wall; said second edge of the second wall being connected to thefirst edge of the fourth wall and forming a right angle corner with thethird wall; said second edge of the third wall being connected to andforming a right angle corner with the fourth wall; a first flange havinga first edge connected to the first edge of the first wall and forming aright angle corner with the first wall; said first flange extending awayfrom the first wall in a direction opposite from the direction that thesecond wall extends from the first wall; a second flange having a firstedge connected to the second edge of the fourth wall and forming a rightangle corner with the fourth wall; said second flange extending from thefourth wall in a direction opposite from the direction that the thirdwall extends from the fourth wall; said first flange having an outersurface; said second flange having an outer surface; and said outersurface of said first flange extending substantially perpendicular tothe outer surface of the second flange.
 5. The sheet metal corner studof claim 4, wherein the first flange has a second edge and said cornerstud further includes a web having a first edge connected to the secondedge of the first flange and forming a right angle corner with the firstflange, and having a second edge; and said corner stud also including athird flange having a first edge connected to the second edge of theweb, and forming a right angle corner with said web and extending inspaced parallelism with the first flange, from said web towards thefourth wall of the stud.
 6. The sheet metal corner stud of claim 4,wherein the second flange has a second edge and said corner stud furtherincludes a web having a first edge connected to the second edge of thesecond flange and forming a right angle with the second flange, andhaving a second edge; and said corner stud also including a third flangehaving a first edge connected to the second edge of the web, and forminga right angle corner with said web and extending in spaced parallelismwith the first flange, from said web towards the first wall of the stud.7. The sheet metal corner stud of claim 5, wherein the second flange hasa second edge and said corner stud further includes a web having a firstedge connected to the second edge of the second flange and forming aright angle with the second flange, and having a second edge; and saidcorner stud also including a third flange having a first edge connectedto the second edge of the web, and forming a right angle corner withsaid web and extending in space parallelism with the first flange, fromsaid web towards the first wall of the stud.
 8. A sheet metal framingassembly, comprising first and second lower channels meeting at acorner, each said channel having a bottom web including first and secondedges and a pair of laterally spaced apart connected to and extendingupwardly from said edges, said channels having a first pair of flangescoming together and defining an inner corner and a second pair offlanges coming together and forming an outer corner; a sheet metalcorner stud at the corner, comprising: a first wall; a second wall; athird wall; a fourth wall; said first wall having a first edge and asecond edge; said second wall having a first edge and a second edge;said third wall having a first edge and a second edge; said fourth wallhaving a first edge and a second edge; said second edge of said firstwall being connected to the first edge of the second wall and forming aright angle corner with the second wall; said second edge of said secondwall being connected to the first edge of the third wall and forming aright angle corner with the third wall; said second edge of said thirdwall being connected to the first edge of the fourth wall and forming aright angle corner with the fourth wall; a first flange having a firstedge connected to the first edge of the first wall and forming a rightangle corner with the first wall; said first flange extending away fromthe first wall and in a direction opposite from the direction that thesecond wall extends from the first wall; a second flange having a firstedge connected to the second edge of and forming a right angle cornerwith the fourth wall; said second flange extending from the fourth wallin a direction generally opposite from the direction that the third wallextends from the fourth wall; said first flange having an outer surface;said second flange having an outer surface; said outer surface of saidfirst flange extending substantially perpendicular to the outer surfaceof the second flange; said sheet metal corner stud including a lower endportion that sets down into the corner region formed by the lowerchannel members; wherein the second and third walls of the corner studare inside bottom track flanges that meet and form an outside corner;and wherein the first and second flanges of the corner stud arecontiguous bottom track flanges that meet and form an inside corner. 9.A sheet metal intersection stud, comprising: a first wall having a firstedge and a second edge; a second wall having a first edge and a secondedge; a third wall having a first edge and a second edge; said secondedge of the first wall being connected to the first edge of the secondwall, said second wall extending perpendicular from the first wall; saidsecond edge of the second wall being connected to the first edge of thethird wall, said third wall extending perpendicular from the second walland in spaced apart parallelism with the first wall; a first flangehaving a first edge and a second edge, said first edge being connectedto the first edge of the first wall, said first flange extendingperpendicular from the first wall; a second flange having a first edgeand a second edge, said first edge being connected to the second edge ofthe third wall, said second flange extending perpendicular from thethird wall towards and in co-planar parallelism with the first flange; athird flange having a first edge and a second edge, said first edgebeing connected to the second edge of the first flange, said thirdflange extending perpendicular from the first flange in a directionopposite the direction that the first wall extends from the firstflange; a fourth flange having a first edge and a second edge, saidfirst edge being connected to the second edge of the second flange, saidfourth flange extending perpendicular from the second flange in adirection opposite from the direction that the third side wall extendsfrom the second flange; said third flange and said fourth flangeextending in spaced apart parallelism with each other; said intersectionstud having a width dimension extending between the outside surface ofthe second wall and the outside surfaces of the first and second flangeswhich is substantially equal to the width dimension between the outsidesurface of the third flange and the outside surface of the fourthflange.
 10. For use with a corner stud that fits into L-shaped cornerportions of upper and lower tracks, a corner comprising: an L-shaped webhaving perpendicular first and second legs having intersecting first andsecond inner edges and intersecting third and fourth outer edges; firstand second flanges extending from the inner edges of the webperpendicular to the web and to each other; third and fourth flangesextending from the third and fourth edges of the web, in the samedirection as the first and second flanges, and extending perpendicularto the web and to each other; and said first leg of the web and saidfirst and third flanges forming one end of the corner fitting and saidsecond leg of the web and said second and fourth flanges forming asecond and fourth corner fitting.
 11. For use with an intersection studthat intersects upper and lower tracks at a location between twocorners, a T fitting comprising: a T-shaped web having an elongatedfirst portion and a second stem portion intersecting the first portionbetween the ends of the first portion, said web having first and secondedges that are perpendicular to each other, a third and fourth edgesthat are perpendicular to each other and a fifth edge that is parallelto the first and fourth edges and perpendicular to the second and thirdedges; first and second flanges connected to the first and second edgesof the web and extending perpendicular to the web and to each other;third and fourth flanges connected to the third and fourth edges of theweb and extending perpendicular to the web and to each other; a fifthflange connected to the fifth edge of the web and extendingperpendicular to the web and the second and third flanges and extendingparallel with the first and fourth flanges; said first and fifth flangesand the web forming a first end of the member; said second and thirdflanges and the web region between them forming a second end of themember; and said fourth and fifth flanges and the web region betweenthem forming a third end of the member; whereby straight sections oftrack may be positioned in line with the first and third ends of themember and a perpendicular section of track may be positioned in linewith the second end of the member.